What are you using for templates for hot wire cutting? I've been using mdf and a jig saw, and it's bloody difficult to get a nice smooth cut, there's got to be a better way... so what is it?
I use benchtop laminate. Gives a nice slick surface for the wire to run over but it can be a pain to cut depending on what tools you use. Try finding a foam supplier which can do it for you. I just send them an autocad drawing these days and it comes back with the rocker and outline cut.
